SolarWorld Kit User guide

www.solarworld.com
03/2013
Translation of the original instruction manual for installers
SolarWorld Kit easy
Standardized solar kit for installation on
pitched roofs.
Planning and Implementation.

2
The SolarWorld Kit easy is a high quality product from the SolarWorld AG product line. The SolarWorld Kit easy
includes all components needed for establishing and operating a solar power system: High quality SolarWorld
solar modules, your choice of inverters, assembly system, wires and accessories.
The following information explains the proper arrangement of the SolarWorld Kit easy, including the Sunfix plus
pitched roof assembly system based on an example. It is intended to help you install the complete system and
avoid any problems.
Please note: Based on tested dimension tables, you are provided a list of permissible construction sites suitable
for the SolarWorld Kit easy. Specific structural features are not considered. In this case, a custom-designed Solar-
World kit must be used.
The compact and high-quality packaging of the SolarWorld Kit easy guarantees quick and hassle-free delivery all
the way to the customer's construction site. The following description provides a step-by-step guide for optimal
and safe unloading of the kit.
Date: 03/2013
Proven quality – simply clever

3
Table of Contents
Safety information A1 Safety notice classification 4
A2 Safety information 5
A3 Information about PV plant design 6
A4 Installation information 7
System description 8
B1 Kit sizes 9
B2 Technical overview 10
B3 Site conditions 10
B4 System arrangement 12
B5 Unpacking instructions 15
B6 Supporting profiles 16
B7 Screw connections 17
B8 Module clamping 18
B9 Roof hook mounting part 19
B10 Equipotential bonding/grounding 21
Mounting example C1 Determination of PV system position and attachment points 22
C2 Installation of mounting components 23
C3 Installation of supporting profiles 24
C4 Solar module installation 25
C5 Module wiring 26
Mounting example Maintenance, repair and cleaning 27
Liability Liability 27
A
B
C
D
E
Page

4
Warning symbol, signal word Warning levels
DANGER! Warns of immediate risk of death.
WARNING! Warns of possible risk of death and/or severe injury.
PRUDENCE! Warns of possible personal injury.
CAUTION Warns of possible property damage without possibility of injury.
Use of additional notice symbols
Indicates additional important information.
Observe applicable accident prevention regulations during installation.
Do not stand or walk on solar modules.
Safety information
A
Read the entire instruction sheet and observe the safety information!
fEnsure that the SolarWorld Kit easy is used only as intended. Observe local standards, building codes and
accident prevention regulations during installation and commissioning. Safety information for other system
components must also be followed.
fNoncompliance with the following instructions may result in electric shock, fire and/or severe injury.
fKeep this instruction sheet in a safe place.
A1 Safety notice classification

5
A2 Safety information
DANGER!
Risk of fatal arcing
fSolar modules generate direct current (DC) when
exposed to light. Breaking a connected string of
modules (e.g., when disconnecting the DC line
from the inverter under load) may result in dange-
rous arcing. Observe the following:
fNever disconnect the solar generator from the
inverter while the inverter is still connected to the
power grid.
fEnsure that the wire connections are in perfect
condition (no cracking, no soiling)!
WARNING!
Risk of falling
fRisk of falling when working on the roof and when
climbing up and down. Observe accident preven-
tion regulations and use suitable fall protection
equipment under all circumstances.
WARNING!
Flammable materials
fSolar modules must not be operated in the vicinity
of equipment or spaces in which flammable gases
or dust occur or can collect.
PRUDENCE!
Risk of hand injury
fHands may be crushed during frame and solar
module installation.
fWork must be carried out by trained personnel
only.
fWear protective gloves!
PRUDENCE!
Beware of falling objects
fTools, mounting materials or solar modules may
fall from the roof during installation and injure
persons below.
fBlock o the area at risk on the ground before
starting installation work and warn persons in the
vicinity.
DANGER!
Risk of fatal electric shock
fSolar modules generate power as soon as they
are exposed to light. The voltage of a single solar
module is less than 50 V direct current (DC). When
several solar modules are connected in series, the
voltages accumulate and can be dangerously high.
When several solar modules are connected in par-
allel, the currents are cumulative. Although touch
protection is provided in the form of the fully insu-
lated plug contacts, the following points must be
observed when handling the solar modules to avo-
id risk of fire, sparking and fatal electric shock:
fDo not install solar modules and lines with wet
sockets and plugs!
fAll work on the lines must be carried out with
extreme caution!
fHigh contact voltages can occur in inverters even
when disconnected!
fCaution is advised in all work performed on the
inverter and lines!

6
Perimeter areas with increased wind loads according
to EN 1991 (Eurocode 1)
According to EN 1991 (Eurocode 1), increased wind
loads must be expected in perimeter areas. These
loads must be taken into account during PV plant
design in addition to snow and design loads. Perime-
ter areas are dimensioned as follows:
e1 = t/10 or h/5, the smaller value is decisive
e2 = b/10 or h/5, the smaller value is decisive
fEnsure adequate load capacity (based on dimensi-
ons, condition and suitable material properties) of
the roof substructure, support structure and other
aected layers (such as an insulation layer).
fObserve the minimum sections of the wood sub-
structure indicated on the instruction sheet. If the
existing wood substructure falls short of these
values, it must be properly augmented to produce
a cross-section equal to a solid cross section with
the required dimensions. In case of doubt, the new,
supplemented wood must exhibit the required
minimum dimensions.
fMake sure that rainwater runo is not impeded.
fConsider physical aspects of the structure (e.g.,
possible water condensation if insulation is pene-
trated).
fIn case of doubt, consult an expert (e.g. a structural
engineer, expert).
fProtect wires installed outdoors from weather,
UV light and mechanical damage using suitable
precautions (such as by using UV-resistant plastic
tubes or wire conduits).
fFor PV plants running parallel to the roof, the solar
modules should be assembled with at least 20 cm
spacing from the roof edge for structural reasons.
Solar modules must never extend beyond the roof
edge!
fAccording to EN 1991 (Eurocode 1), increased wind
loads must be anticipated at the roof edges due to
peaks in wind suction, which can raise the moun-
ting components in these areas.
A3 Comments regarding PV plant design

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fObserve applicable accident prevention regulati-
ons during installation.
fAll persons who are on the roof of a building at
least 3 m tall must use fall protection.
fUse barriers to protect persons on the ground
below from falling debris.
fAlso obey the safety instructions for all other
system components (e.g., inverters and solar
modules).
fThe PV plant must be connected to the public
power grid by a professional electrician only.
fObserve the instruction sheet for solar modules
and inverters included in the delivery as well as the
mounting and wiring diagram.
fEnsure that all screw connections are securely tigh-
tened.
A4 Comments regarding installation
Fire protection
Local fire protection regulations are to be observed
during planning and arrangement.
Information about fire break and party walls
Dierent requirements under planning and building
laws apply to the design of PV systems depending
on building class or type and use of special purpose
buildings.
In general, the following applies:
1. The functionality of fire break and party walls
must not be impaired.
2. PV modules must not be installed over fire break
and party walls.
3. A sucient gap is to be maintained between PV
systems and fire break and party walls. This gap
can be determined by an expert.

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Proper and improper use
System description
B
Proper use
The SolarWorld Kit easy includes the Sunfix plus
assembly system used to ax solar power modules
onto roofs of standard construction and height.
Proper use includes observing the instruction sheet
and compliance with maintenance, repair and
cleaning instructions. The manufacturer does not
accept liability for damage resulting from failure to
adhere to the instruction sheet.
Improper use
This list does not include all conceivable types of
improper use and thus does not make any claim of
completeness. The information supplied is intended
merely to provide a sense of what constitutes impro-
per use.
fThe instructions in this installation manual were
disregarded.
fThe assembly system was:
• Not used properly to secure the solar power
modules,
• Not installed according to the framework con-
ditions of this instruction sheet (such as for
attachment to a facade)
• Improperly assembled,
• Maintained improperly or not at all,
• Modified,
• Exposed to improper design loads.
fRepairs were improperly carried out.
fThe PV plant was combined with components from
other manufacturers.

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B1 Kit dimensions
The SolarWorld Kit easy is available in three dierent
sizes, including 16, 20 and 24 solar modules. There are
several arrangement options for each of these sizes.
16 solar modules (4 kWp)
Arrangement option 2 x 8 solar modules 4 x 4 solar modules
Minimum roof area 3.9 x 8.5 m 7.3 x 4.5 m
20 solar modules (5 kWp)
Arrangement option 2 x 10 solar modules 4 x 5 solar modules 5 x 4 solar modules 2 x 5 + 2 x 5 solar modules
Minimum roof area 3.9 x 10.5 m 7.3 x 5.5 m 8.9 x 4.5 m 3.8 x 5.5 m + 3.8 x 5.5 m
24 solar modules (6 kWp)
Arrangement option 2 x 12 solar modules 3 x 8 solar modules 4 x 6 solar modules 2 x 6 + 2 x 6 solar modules
Minimum roof area 3.9 x 12.6 m 5.5 x 8.5 m 7.3 x 6.5 m 3.9 x 6.5 m + 3.9 x 6.5 m

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Fig. B 2-1 Sample frame diagram for 4x4 arrangement option Fig. B 2-2 Sample DC wiring diagram for 4x6 arrangement option
The SolarWorld Kit easy includes the Sunfix plus
assembly system from SolarWorld AG in a single-layer
design. The assembly system is a flexible support
structure for installing solar power modules on pit-
ched roofs parallel to the roof line. The kit is assem-
bled so that the assembly options described in B1 can
be realized under various framework conditions.
In addition to this instruction sheet, you can visit us
at www.solarworld.com and download the document
"Installation information". There you will find the
most important documents for all kit sizes and arran-
gement options needed for installation and commis-
sioning: Frame diagram, DC diagram and potential
equalization diagram.
B2 Technical overview
The SolarWorld Kit easy is available in three dierent sizes.

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B3 Location conditions
General boundary conditions
Roof type Rooftop cover Rafter spacing Roof pitch Roof battens
Pitched roof Tile 60 to 80 cm 15° to 50° 24 and 30 mm
Wind load kN/m2Snow load kN/m2
(distance between rafters: 80 cm)
Snow load kN/m2
(distance between rafters: 60 cm)
0,60 1,75 2,45
0,80 1,60 2,35
1,00 1,40 2,25
1,05 1,30 2,15
1,20 Not possible 2,00
SolarWorld Kit easy can be used in areas with the following wind and snow loads according to EN 1991:

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B4 System arrangement
Fig. B 4-1
A
Fig. B 4-2 Module clamping edge Fig. B 4-3 Center module clamping
B
B
C
43
4
2
19
A

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Component list of the SolarWorld Kit easy
incl. Sunfix plus
Pieces
16 solar
modules
20 solar
modules
24 solar
modules
1Supporting profile 2080 mm TD2080 16 20 24
2Fastener set yellow (slot nut) SA0173 60 78 94
3End piece SA0177 17 21 17
4Module clamping SA0192 41 52 58
5Roof hook SD0027 56 72 88
6Adapter plate medium roof hook SD0064 56 72 88
7Profile connector SK0135 13 17 21
8M8x16 screw SK0145 60 78 94
9Universal profile connector SK0148 13 17 21
10 Earthing clamp SK0372 4 5 4
11 M8x100 wafer-head screw SK5215 116 150 182
12 M8x24 screw SK0147 60 78 94
13 M8 flange nut SK5012 60 78 94
14 Flange plate for add. adjustability SA0226 56 72 88
15 Profile end cover SA0595 16 20 16
16 Suncable SK5236 60 120 120
17 MC4 plug SA0139 2 4 4
18 MC4 socket SA0143 2 4 4
19 Solar module 16 20 24
20 Inverter 1 1 1
Fig. B 4-4 Fastening to roof
Fig. B 4-5 Profile connector
9 7
11 258
1
C

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SolarWorld Kit easy partial package list
C1/2
E4/5/6
G2/3
Ext. No. Description Pieces
TD2080 Supporting profile 2080 mm 4
SA0173 Fastener set yellow (slot nut) 13 8
SD0027 Roof hook Medium 0-24 12 8
SK0145 Screw similar to DIN 603 M8x16 13 8
SK5215 8x100 wafer-head screw 25 16
SK0147 Screw similar to DIN 603 M8x24 13 8
SK5012 M8 A2 flange nut 13 8
SA0226 Flange plate for add. adjustability 12 8
SD0064 Adapter plate medium roof hook 12 8
SA0177 Edge end piece 30.5 mm 17 21 17
SA0192 Module clamping middle 31 mm 41 52 58
SK0135 Profile connector 1 13 17 21
SK0148 Universal profile connector 13 17 21
SK0372 Universal earthing clamp 4 5 4
SA0595 End cap for Fix Plus 1 frames 16 20 16
SK5236 Suncable 1x6 PV1-F 60 120
SA0139 MC4 plug type 4/6II 2 4
SA0143 MC4 plug type 4/6II 2 4
A1
SolarWorld Kit easy package list
Box A1 C1 C2 E4 E5 E6 G2 G3
16 solar modules 4 4 1 1 1
20 solar modules 5 6 1 1
24 solar modules 6 6 2 1 1
Fig. B 4-8
Fig. B 4-7
Fig. B 4-6
Fig. B 4-9

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B5 Unpacking instructions
Numbers ( to ) are printed on the packing tapes, which are to be cut open sequentially in order to ensure
safe unloading.
Remove mounting profiles
Remove the 4-count solar module packages one by oneto
Remove boxes holding small parts Unload inverter
110
1
410
23
CAUTION!
fThe final eight solar modules are not positioned
securely on the pallet. Secure using a second per-
son!
Fig. B 5-1 Fig. B 5-2 Fig. B 5-3
Fig. B 5-6Fig. B 5-5Fig. B 5-4
Fig. B 5-7

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B6 Supporting profiles
The Sunfix plus assembly system is used as a single-layer subframe in the SolarWorld Kit easy.
The "flange plate for additional adjustability" can be used if the substructure is uneven.
Fig. B 6-1 Profile distances
1100 mm
9 mm
584 mm
fThe distance between supporting profiles under
a row of solar modules is set at 1100 mm. This can
vary according to the solar module instructions.
The individual frames are joined to one another
lengthwise using profile connectors. By default, the nar-
row profile connector is inserted in the side groove.
Fig. B 6-2 Profile connector 1 and 2, side assembly
Fig. B 6-3 Detail 1
Frames without direct fastening not possible!
Fig. B 6-3 Detail 2
Frames with 1 fastener - not possible!
Fig. B 6-3 Detail 3
Frames with 2 fasteners - OK!
Connector Connector Fastening Connector Fastening
Fastening
According to the frame diagram, each profile requires
at least 2 fasteners to the roof construction.

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B7 Screw connections
The connections between mounting parts (such as
roof hook, angle flange, etc.) and the supporting pro-
files and between the supporting profiles are screwed
connections with M8 screws and slot nuts with pla-
stic tabs.
Assembly:
1. Insert fastener set yellow.
2. Turn the assembly tool 90° using the plastic tab.
Fig. B 7-2
Fig. B 7-4 Fig. B 7-5
1
5
N
m
Fig. B 7-3
90°
1M8x16mm screw with T40 driver
2Fastener set yellow (slot nut with yellow plastic tab)
Fig. B 7-1
1
2
3. Position the fastener set yellow on the mounting
parts using the plastic tab.
4. Screw in and tighten the M8 screw.
15 Nm torque

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B8 Module clamping
Fig. B 8-2 Inside module clamping
Solar modules are fastened by clamping. A torque
wrench is recommended to ensure the required force.
Firmly tightened stainless steel screws may be
impossible to remove without destroying them.
Carefully align and position the solar modules
exactly before tightening the screws using the
indicated torque!
Spot-check the screws annually for required tor-
que!
Fig. B 8-8 Turning module clamping
Fig. B 8-3 Module clamping
1
21End piece
2Clamp element
Fig. B 8-9 Place second solar module, tighten screw
Fig. B 8-1 Module clamping edge
1
2
2
End-clamp mounting
Fig. B 8-5 Slide on end piece
Fig. B 8-4 Slide on module clamping
Fig. B 8-6 Tighten screw
Mid-clamp mounting
Fig. B 8-7 Insert module clamping
90°
15 Nm
15 Nm
Torque MA= 15 Nm
Driver for module clamping: T40
35 mm

19
Fig. B 9.1-1 Roof hook 0°
2
4
3
6
B9 Roof hook mounting part
The roof hook fastener set is suitable for most common
types of roof tiles, such as Frankfurt pan tile, interlocking
tile, Taunus pan tile, etc.
1Supporting profile
2Screw similar to DIN 603 M8x16
3Fastener set yellow
4M8 A2 flange nut
5Screw similar to DIN 603 M8x24
6Flange plate for add. adjustability
7Roof hook
8Wafer-head screw
9Adapter plate medium roof hook
10 Rafters
11 Counter battens
12 Roof battens
Roof hook technical data
Possible roof batten dimensions
24x48mm ("short")
30x50mm ("standard")
For 30 mm batten cross-sections, the base plate of
the roof hook must be underlaid using the enclosed
adapter plate.
Fastening to wood substructure 8x100mm wafer-head screw (standard)
Req. embedding depth of wafer-head screws in the
wood substructure 60 mm
Minimum wood rafter dimensions w x h 60x100mm (8x100mm wafer-head screws)
Fastening angle to frame 0° to (see Fig.)
Types MEDIUM (height adjustable 14 mm)
Driver for wafer-head screw T40
At maximum load, the roof hook positions itself
directly on the rooftop cover. In the unloaded state,
the distance between the roof hook and tiles must be
≥ 5 mm.
Fig. B 9.1-2
1
4
12 811
10
1
7
8
9
5

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Assembly:
Fig. B 9.1-3
Fig. B 9.1-4
Fig. B 9.1-6
1. Remove tile above hook location
2. Position arm of roof hook at the bottom of the tile
space and fasten to rafter with 2 screws. A space
≥ 5 mm must be left between tile and hook. In the case
of 30 mm battens, the base plate must be underlaid
using the enclosed adapter plate.
3. Grind out back of tile and replace onto roof. With
interlocking tiles, the tile below must also be recessed.
Fig. B 9.1-5
≥ 5 mm